RC Operator Manual

3000
S E R I E S

This operator manual

has information for the

following RC model

along with some options

and accessories. Some

illustrations and

informa tion may not

a pply to your truck.

The most
important
component
is you.

New Bremen, Ohio 45869 USA © 1996 PF12398-WEB Rev. 6/06 Printed in U.S.A.
RC 3000
S E R I E S
 You Must be Certified

IT'S THE LAW, YOU MUST BE TRAINED AND CERTIFIED

STOP
Federal law states that only properly trained operators are
permitted to operate a powered industrial truck and that
It’s the law, you must be trained and certified to your employer must train you and certify that you are
operate this truck. (OSHA § 1910.178, Rev. 1999) qualified to operate this powered industrial truck.
(OSHA §1910.178, Rev. 1999)
You or others around you can be seriously injured or even killed
if you don't use this truck correctly.
Do not operate this truck in your work place until you
Read and obey all warnings and instructions in this Manual* and have been certified by your employer.
on the truck.

Head, arms, hands, legs or feet outside the operator area can be
pinned or crushed whenever the truck is moving. Stay within the
operator area and stop the truck completely before getting off.

However, tipovers and falls from docks can cause serious injury
or even death. Immediately exit and move away from the truck You could be killed or seriously injured if you are not
in these emergencies.
adequately trained for lift truck operation!
You can be trapped or crushed by driving the operator area under
racks or other objects. Look where you are going.

Inspect your truck before starting work, make sure it is in good

working order.
* Additional copies of this Operator Manual and all Truck Labels can be obtained
from Crown Equipment Corporation, New Bremen, Ohio 45869 U.S.A.

All rights reserved under International

and Pan American copyright conventions
Copyright 1996 Crown Equipment Corp.

1 Warning You Must be Certified 2

Protect Yourself
Know the Hazards
DRIVE CAREFULLY
• Keep your hands on the controls and feet on the pedals.
Keep your entire body in the operator area.
• Never stick a foot or any part of your body outside the
operator area, no matter how slow the truck is moving.
You cannot stop 3630 kg (8000 pounds) with any part
of your body. A foot or hand caught between the truck
and a fixed object will be crushed or even cut off.
• Stay away from the edge of docks and ramps. Make
sure dockboards are secure. Check that trailer wheels
are chocked. You could be seriously injured or even
killed in a fall from a dock or dockboard.
• Keep your truck under control at all times. Drive at
a speed that allows you to stop safely. Be even more
careful on slippery or uneven surfaces. Do not drive
over objects on the floor.
LOOK WHERE YOU'RE DRIVING
• Always be alert to the area around you and watch where
you are driving. You could be pinned or crushed by
objects intruding or poking into the operator area.
3 Protect Yourself
Know the Hazards
AVOID FALLS AND TIPOVERS
Falls from docks and tipovers are very serious accidents;
you can be crushed or even killed. Immediately exit and
move away from the truck in these emergencies.
Note: This is not like sit-down rider trucks, where it is
recommended that the operator stay with the truck.
The best way to prevent injury is to know where you are
at all times and follow the rules of safe truck operation.
• Be extremely careful when working around docks,
dockboards and trailers.
• Use forward tilt only when you have the load over a
stack or close to the floor.
• Travel with the load or forks close to the ground and
tilted back. Watch for overhead obstructions. Perform
all truck movements smoothly and at a speed that will
give you time to react in an emergency.
• An unloaded truck can tip over also. Be just as careful
using an unloaded truck as you are using a loaded one.
USE YOUR TRUCK SAFELY
WARNING • Keep your hands and feet away from all moving parts
Stay clear of all such as masts, chains, forks or wheels. Make sure the
moving parts.
overhead guard and load backrest are in place.
Moving parts can
cut or crush hands,
feet, arms or legs.
• Never stand on or under the forks, or allow anyone else
to stand on or under them. The only way to lift people
is with an approved platform. Never allow passengers
on the truck. There is no safe place for them.
• Before you leave your truck:
• Come to a complete stop and lower forks to the floor.
• Shut the truck off with the key or power disconnect.
Protect Yourself 4
Contents What's in it for You?
WHAT'S IN IT FOR YOU?
The better you understand your truck and how to use it,
the better and safer operator you can be. Here are some
Warning 1 guides to using this manual.
You Must be Trained 2
Protect Yourself 3
Contents 5
Capacity & Load Center QUICK LOCATORS
In addition to the "Contents" page
What's in it for You? 6 you can use page headings to find
Your Stand-Up Rider 7 topics. Some pages also have a picture
Know the Hazards
of the truck in the corner showing
Lift Truck Parts 9 Units of measure, kg/mm (lb/in)
Truck Weight with Max. Battery features or functions covered on that
RC 4075(8985)

Capacity & Load Center 11

Truck Type

page.
E
3000 Attachment Data
SERI ES

SIDESHIFTER
Serial Number
Load A1234567

Capacity Plate 13
Capacity with Mast Vertical
Center
Capacity

"KNOW THE HAZARDS"

1405(3100) 4370(172) 600(24)
1450(3200) 3910(154) 600(24)
1020(2250) 4370(172)
1045(2300) 3910(154)
403-B

Power On & Off 15 Watch for and read these special

blocks. You will find information
Foot Brake 17
about possible safety hazards and how
Traveling & Plugging 19 to avoid them.
Steering & Travel 21 HOW-TO-DRAWINGS
Two Types of Steering 23 On many pages you will find pictures
Fork Function 25 as well as text to help you understand

E
PL
how to use your truck safely and
Retractable Guard optional 27

M
productively.

SA
Hydraulic Accessories 28
Daily Safety Check 29 11 Capacity & Load Center Capacity & Load Center 12

Be a Safe Driver 31
Battery Maintenance 35
Warning Labels 38

5 Contents What's in it for You? 6

Lift Truck Parts

Accessory Levers
(Optional)

Battery Charge Meter Overhead Guard

Key Switch Tilting Mast

Hour Meter

Multi-Function
TILT

Information

Retractable Guard
Control (Optional)

Power Disconnect

Multi-Function Handle Battery

Back Pad Power Unit

Power-On Pedal
Steering Handle
Brake Pedal
Capacity Plate
Battery Retainer

Steer Wheels
Drive Wheel
Load Backrest
Fork

9 Lift Truck Parts Lift Truck Parts 10

Capacity & Load Center

Center of evenly
WHAT IS YOUR TRUCK CAPACITY?
Know the Hazards
distributed load
Capacity is the load (including pallet or
container) that can be lifted to a given height
at a given load center. See the capacity plate on
your truck. Make certain you use the correct units RC
Units of measure, kg/mm (lb/in)
Truck Weight with Max. Battery
4075(8985)
KNOW YOUR LOAD
600mm
(24 in.) Max of measure. 3000
Truck Type
E
Attachment Data
Do not exceed the capacity shown on your truck's capacity
SERI ES

SIDESHIFTER
plate. Be careful when handling long, high or wide loads.
Load WHAT IS LOAD CENTER? Load
Serial Number
A1234567 Do not handle unstable loads.
Center
Capacity with Mast Vertical

Load center is the distance from the load backrest or

Center
Capacity

EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT

1405(3100) 4370(172) 600(24)
1450(3200) 3910(154) 600(24)
vertical face of the fork to the center of an evenly 1020(2250)
1045(2300)
4370(172)
3910(154)

distributed load. 403-B

Know the capacity of your truck as shown on your capacity
plate. Make certain you use the correct units of measure.
Pay attention to:
• Weight of load
• Load center
LOADS MUST BE EVENLY DISTRIBUTED
• Lift height
Your truck could tip over, in any direction, if a load
is shifted to the front or side of a pallet or container. HYDRAULIC OPERATIONS CAN AFFECT STABILITY
Capacities given on your capacity plate are for loads that
are centered and level. Be extra careful when tilting a
load. (This also applies to other accessories or attachments
your truck may have, such as sideshift, carton clamp,
push-pull, etc.)

CENTER THE LOAD

Your truck could tip over if a load is shifted to the front
or side of a pallet or container. Make sure your load is
evenly distributed and centered over the forks.

11 Capacity & Load Center Capacity & Load Center 12

Capacity Plate

CAPACITY PLATE INFORMATION

The capacity plate is on a console in
the operator area. It contains:
• Serial number
• Capacity information (load, load center and lift height)
• Truck type (a fire safety rating)
• Truck weight with battery (does not include load)
• Attachment information (if any)

READING YOUR CAPACITY PLATE

Capacity may be reduced as lift height A increases.
For example: On the sample plate, 1450kg (3200 lb) can Know the Hazards
be lifted to 3910mm (154 in.). But above 3910 (154),
to 4370 (172), capacity is reduced from 1450 (3200) to
1405 (3100). TRUCK WEIGHT
Capacity is reduced as load center B increases. Dockboards, elevators and some floors have limited
SAMPLE
CAPACITY PLATE For example: On the sample plate, 1450kg (3200 lb) can capacity. Check your capacity plate for the weight of
The information shown be lifted if the load center is 600mm (24 in.) But if the your truck. Make certain you use the correct units of
on this sample plate load center is increased to 830mm (33 in.), capacity is measure. Remember to add the weight of the load
does not apply to your
reduced from 1450 (3200) to 1045 (2300). you have on the forks.
truck.
Units of measure, kg/mm (lb/in) CAUTION ATTACHMENT DATA
Truck Weight with Max. Battery
RC 4075(8985) You may not increase capacity if load If an attachment on your truck does not match the
Truck Type center is less than shown on your information given here on your capacity plate, don't operate
E
3000 Attachment Data capacity plate. your truck. Your capacity plate may be wrong. Report
SERI ES
the problem to your supervisor.
Note: ANSI B56.1 requires that all
LE

SIDESHIFTER
MP

Serial Number data be shown first in Metric units and TRUCK TYPE
SA

Load A1234567
Center
Capacity with Mast Vertical then USA units. Some truck types are not permitted in areas where there
Capacity
1405(3100) 4370(172) 600(24)
are fire hazards. Watch for marked areas. For example:
1450(3200) 3910(154) 600(24) You must not drive a type E or ES truck in an area restricted
1020(2250) 4370(172)
1045(2300) 3910(154) to EE or EX trucks.
403-B

13 Capacity Plate Capacity Plate 14

Power On & Off

KEY SWITCH ENTRY BAR

• Turn the key clockwise to the green dot Keep your feet in the operator area and clear of entry bar.
to turn the truck ON. If you put your foot on the entry bar while traveling, the
• When leaving the truck, turn the key back to the red dot alarm will sound a warning and travel speed is limited to
to to shut the truck OFF. 2.4km/h (1.5 mph). Plugging is reduced. Braking is not
affected.
Below 2.4km/h (1.5mph) the alarm will sound a warning
but travel speed, plugging and braking are not affected.
POWER-ON PEDAL
Step down on the right pedal. If the key is turned ON,
the steering pump will start running and you can operate
the truck.
Note: You must keep the power-on pedal down for power
steering to work.

POWER DISCONNECT
Push the Power Disconnect in the direction of the forks
to disconnect the battery and cut all power.
Always use the Power Disconnect any time the truck isn't
working right. The key switch does not cut all power to
the truck.
Don't use the truck if it's not working right. Report the
Know the Hazards
problem to your supervisor.
BEFORE CONNECTING THE BATTERY
BATTERY CHARGE METER
WARNING Make certain the block (Crown #77034) is bolted to the
Attach block #77034 to Emergency disconnect
The lighted bar shows how much charge is left in your Battery Connector
lever will not work if back of the battery half of the connector. Without that
block #77034 isn't
battery. A flashing light will warn you that the battery is bolted to the battery block the Power Disconnect won't work. In an emergency
half of the connector.
getting low. Two flashing lights mean you must have the you will not be able to cut power to the truck.
Never use a battery
battery changed or recharged. Use (2) 1/4 x 1-1/4
screws, lockwashers
& nuts.
without the block in
place.
34

15 Power On & Off Power On & Off 16

Foot Brake

BRAKES OFF
Step all the way down on the left pedal.
The brakes are now "off" and you can travel.
Note: Slowing or stopping the truck by plugging (see
page 19), requires power to the drive motors. You must
have the brake pedal all the way down for plugging to Know the Hazards
work.
BRAKES ON WATCH YOUR FEET
Lift your left heel. Let the left pedal rise until you have Keep your feet inside the truck and on the pedals at all
the desired braking force. Let the pedal come up all the times. This truck weighs about 3630kg (8000 pounds)
way for full braking. even without a load. You cannot stop or even slow down
that much weight with your foot or any part of your body,
As the brake pedal starts to lift, power is cut to the drive no matter how slow the truck is moving.
motors. Remember, without power to the drive motors
you can't use plugging. A foot or hand caught between the truck and a wall, post
or any fixed object will be crushed or even cut off.

MAKE SURE YOUR BRAKES WORK

?
Test the brakes on your truck at the start of each shift.
Know the distance it takes to stop before you start
working.
If at any time the stopping distance is too long for you to
stop safely, don't drive the truck. Report any problem to
your supervisor.

17 Foot Brake Foot Brake 18

Traveling & Plugging
Pull the
multi-function
control

Travel, Travel,
TILT
forks first power unit first

Push the
multi-function
TRAVEL, POWER UNIT FIRST control
Pull the multi-function handle toward you to
travel in the direction of the power unit (power HORN
unit first). Press the blue button on the multi-function handle to
The farther you pull the handle from the neutral sound the horn. Use it to warn pedestrians and other
position, the faster the truck will travel. drivers.
Use your horn when you come to an intersection or a
crosswalk.
TRAVEL, FORKS FIRST
Push the multi-function handle away from
you to travel in the direction of the forks
(forks first). Know the Hazards
The farther you push the handle from the
neutral position, the faster the truck will travel.
PLUGGING VS. BRAKING
Of the two, the foot brake is designed to stop the truck in
PLUGGING the shortest distance. Use the foot brake in an emergency,
Plugging is another way to slow down or on ramps or in busy areas.
stop your truck.
While the truck is moving, in either direction, YOU CAN'T HAVE BOTH
pull or push the multi-function handle through Plugging works only when you have the brake pedal all
neutral to the opposite direction of travel. the way down. When the brake pedal begins to lift, power
is cut to the drive motor and you will not be able to plug.
This will not hurt your truck.

19 Traveling & Plugging Traveling & Plugging 20

Steering & Travel

LIFT TRUCKS ARE NOT LIKE AUTOMOBILES

Your lift truck does not steer or drive like an
automobile. Be sure you are trained to operate
this truck. Drive slowly until you get used to the
steering and all other controls.

STEERING AND DRIVING

You will need to drive your truck both in the direction of
the forks (forks first) and also away from the forks (power
unit first or forks trailing). Steering is not the same in
both directions. Be careful.

Know the Hazards

SIMILAR TRUCKS CAN BE DIFFERENT
This style truck can be built with one of two different types POWER UNIT SWING
of steering. Your company has selected the type which is
Be careful turning while traveling forks first. The power
best for your work area.
unit will swing wide in the opposite direction. Make sure
Caution: If you ever drive a different truck, even one that you have clearance, and watch out for people in the area.
looks just like yours, be careful. The steering may be
different (see pages 23 and 24).

SLOW DOWN FOR SPILLS OR WET FLOORS

Powder or liquid spills can cause slippery floors. Slow
down or you could lose control of steering and braking.
Be careful and allow for a longer stopping distance.
Don't run over objects on the floor.

21 Steering & Travel Steering & Travel 22

Two Types of Steering

THERE ARE TWO TYPES OF STEERING

This style truck can be built with one of two different types of steering.
Your company has selected the type which is best for your work area.
Caution:
• Don't drive if you have not been trained.
• Your truck does not steer like an automobile.
• Drive slowly until you get use to the truck.
• Trucks that look like yours may steer differently.

1 REAR DIRECTIONAL STEERING (Sometimes called Reverse Steering.)

Shows direction truck will turn when steering handle is turned clockwise. 2 FRONT DIRECTIONAL STEERING (Sometimes called Forward Steering.)
Shows direction truck will turn when steering handle is turned clockwise.
Dir f T

Tu t i o n

ur t io n
o

rn
ec

re
c

Travel, power n Di o f Travel, Travel, power Travel,

n Di forks first
unit first forks first unit first io of r
rn

of ct

ec u r n
D i re

t io
Tu

T
n
23 Two Types of Steering Two Types of Steering 24
Fork Function

AVAILABLE FORK OR LIFT UP MULTI-FUNCTION

HYDRAULIC FUNCTIONS
Raising and Lowering the forks plus Fork Tilt
TILT are standard. You control these two functions with the
multi-function handle.
Your truck may also have accessory functions like Sideshift,
Carton Clamp or Push-Pull. You control these functions
with the accessory control levers.
Use these hydraulic functions when you move, put away
or take down loads.
RAISE/LOWER
You are always in the Raise/Lower function unless you
select the Fork Tilt function.
SELECTING FORK TILT
Press the orange button on the multi-function handle to
select Fork Tilt.
Note:
• You are always in the Raise/Lower function when you
turn the truck on.
• You must have the handle in neutral to select Tilt.
• You must hold the orange button in until you move the
handle from neutral and the forks and mast start to tilt.
Select a function and lift the multi-function handle up.
The forks will raise or the forks will tilt up (mast will tilt
back), depending on which function you selected.
The further you lift the handle up, the faster the movement
will be.
NEUTRAL
You must have the control in neutral to select the Tilt
function. Hold the orange button in until you move the
control and the mast starts to tilt.
Return the handle to neutral and you will be back in the
Raise/Lower function.
PUSH DOWN MULTI-FUNCTION
Select a function and push the multi-function handle down.
The forks will lower or the forks will tilt down (mast will
tilt forward), depending on which function you selected.
The further you push the handle down, the faster the
movement will be.

25 Fork Function Fork Function 26

Retractable Guard optional Hydraulic Accessories

RETRACTABLE OVERHEAD GUARD

Turn the knob clockwise to lower the Hydraulic accessory levers (optional)
guard about 150mm (5.9 in.). Turn the
knob counterclockwise to raise the guard. HYDRAULIC ACCESSORY OPERATION
Lower the guard if you must work in areas with low Pull the lever toward you and you'll get the action shown
overhead clearance. Always raise the guard for overhead by the symbol in the top of the knob. Push the lever away
protection whenever you leave a low clearance area. from you and you'll get the opposite action.
For example: If you have a Sideshift accessory,
2300mm (90.5 in.) raised height
pull the lever toward you to shift the forks to
2150mm (84.6 in.) lowered height the right, or push the lever away from you to
shift the forks to the left.
OPERATING LIMITS
• You cannot lower the guard if you have the forks raised
above operator compartment height.
• You cannot raise the forks above operator compartment
height if you have the guard lowered.

Know the Hazards

CHECK OVERHEAD CLEARANCE
Know the height of your truck and when you must lower
the guard to clear low obstructions.

PROTECT YOURSELF
Falling objects can cause injury. Always raise the retractable
guard when you leave a low clearance area.

WATCH YOUR HEAD WHEN THE GUARD IS DOWN

Look where you're going and check for objects that could
intrude or poke into the operator area.

27 Retractable Guard optional Hydraulic Accessories 28

Daily Safety Check
CHECK YOUR TRUCK BEFORE STARTING WORK
You must make sure your truck is safe to use.
1. Walk around your truck and check it over.
• Check to make sure the battery is charged, water level
is OK and vent caps are in place. Don't use an open
flame to check the battery.
• Make certain the battery retainers on both sides of the
truck are properly installed.
• See that all wheels are in good condition.
• Check that both forks are secure and not bent, cracked
or badly worn.
• Inspect lift chains for damage.
• See that the load backrest and overhead guard are in
place and fastened.
• Look under the truck for signs of hydraulic leaks.
• Test the horn.
• Make sure the power disconnect works.
29 Daily Safety Check
2. Test drive your truck in an uncongested area.
• Try all the hydraulic functions.
• Check that the steering is easy and smooth.
• Drive the truck slowly in both directions.
• Drive through the full speed range in both forward
and reverse.
• Check braking and plugging distances in forward
and reverse. Load size and floor conditions can affect
these distances.
• Know the distance it takes to stop before you start
working. If the braking distance is too long to stop
safely, don't drive the truck.
If anything doesn't look or feel right, don't drive the truck.
Report the problem to your supervisor.
You can get checklist forms from your Crown dealer
(part no. OF-3772). Used properly, this checklist can alert
service people to needed repairs.
Daily Safety Check 30
Be a Safe Driver
MAKE SURE YOU ARE READY TO DRIVE
The most • Do not use this truck unless you are trained
and certified.
important • Be certain you understand how your truck works and
the hazards that go with it. Don't drive the truck if you
component have any doubts.
• Know the capacity of your truck (Load Weight, Load
Center and Lift Height). Make certain you use the
is you. correct units of measure.
• Some trucks are not allowed in areas where there are
fire hazards. Be certain your truck is the correct fire
safety type for the area.
• Make sure your hands and shoes are clean and dry, and
your clothing is proper for the job.
MAKE SURE YOUR TRUCK IS READY
• Inspect your truck before using it (see pages 29 and 30).
If it's not working right, or something is broken, report
the problem to your supervisor. Don't use the truck.
• In an open area, test the brakes and plugging. Check at
a slow travel speed first, then a faster one. Know the
distance it takes to stop before you start work.
31 Be a Safe Driver
DRIVE CAUTIOUSLY, BE ALERT
• Never stick a foot or any part of your body outside the
operator area, no matter how slow the truck is moving.
You cannot stop 3630 kg (8000 pounds) with any part of
your body. A foot or hand caught between the truck and
a fixed object will be crushed or even cut off.
• Keep your hands on the controls and your feet on the
pedals.
• Travel in the direction that gives you the best view. Look
where you are going and slow down in congested areas.
• Slow down for wet or slippery floors. Don't run over
things.
• Travel with the forks close to the ground, retracted and
tilted up. Place the load against the load backrest (vertical
face of the forks).
• Look where you are going before you change direction
of travel.
• See that you have room to drive and turn. Always check
for overhead objects. Watch out for power unit swing.
• Slow down when making turns.
• Avoid sudden movement of controls. Learn to use them
smoothly at a moderate, even rate.
• Check clearances before raising or lowering the forks
or load.
• Be extra careful if you must use your truck in an area where
there is a risk of falling objects. Don't operate your truck
with the retractable overhead guard lowered.
Continued next page...
Be a Safe Driver 32
Be a Safe Driver continued
WATCH OUT FOR OTHER PEOPLE
• Slow down. Yield or stop for pedestrians.
Use your horn when you come to a crosswalk
or intersection.
• Be careful that you don't pin or crush someone.
For example: Never drive your truck toward anyone
standing in front of a fixed object.
• Never allow passengers on your truck.
• Watch out for power unit swing.
• Keep others away from your truck while you're working.
Don't ever allow anyone on or under the load or forks.
• Don't let anyone use your truck unless they are trained
and certified.
• Never lift anyone with the forks unless they are using
an approved platform. Even then use extreme caution:
• Use a securely attached and approved safety platform.
• Make certain lifting mechanism is operating properly.
• Have load backrest vertical (never tilt when elevated).
• Make certain truck is in neutral and brake is applied.
• Lift and lower slowly.
• Watch for overhead obstructions.
• Be sure you can see and hear the person being lifted.
• Never transport anyone on the platform from one
location to another.
33 Be a Safe Driver continued
AVOID FALLS AND TIPOVERS
• Stay away from the edge of docks and ramps.
• Check that bridgeplates and dockboards are secure. Be
certain that either the trailer wheels are chocked or the
trailer is locked to the dock. Check capacities. Be sure
your truck, with load, isn't too heavy for where you are
driving.
• Make sure the load you are moving is stable. Spread
the forks as far as you can and center the load. Insert
the forks as far under the load as you can. Be even more
careful with long, high or wide loads. They can be less
stable.
• Use forward tilt only when you have the load over a
stack or close to the floor. Use minimum fork tilt to
pick up or place a load. When lifting or lowering
outside a rack, keep the load backrest vertical or tilted
back slightly.
• When moving loads on grades or ramps, drive with your
forks pointed upgrade. Without a load, drive with forks
downgrade. Slow down, and don't turn on grades or
ramps.
LEAVING YOUR TRUCK
• Stop your truck completely before getting off.
• Lower the forks to the floor. Turn the truck off or
disconnect the battery.
• Avoid parking on inclines. But if you must, block the
wheels of your truck.
Be a Safe Driver continued 34
Battery Maintenance
WHEN YOU INSTALL OR CHANGE BATTERIES
• Turn the truck OFF. Check that all controls
are in neutral.
• Make certain you use the correct size and weight
battery. Never operate a truck that has an underweight
or undersize battery installed.
• Use a roller stand to install or remove a battery. Make
sure the roller stand is the same height as the rollers in
the truck's battery compartment. Also make sure the
roller stand is at least as long as your battery.
• Never let anything metal touch the top of the cells.
You could cause sparks or do damage to the battery.
Use an insulator (such as plywood) when necessary.
• Use an approved spreader bar to place a battery on, or
remove it from a stand. Make sure you adjust the
spreader bar hooks to fit the battery.
AFTER INSTALLING YOUR BATTERY
• Replace the battery retainer. Make certain the retainers
on both sides of the truck are in place.
• Be sure the block #77034 is bolted to the back of the
battery half of the connector.
• Connect the battery. Turn the truck ON and check truck
operation.
35 Battery Maintenance
Know the Hazards
TRUCK BATTERIES CAN BE DANGEROUS
DANGER Your truck battery produces fumes that can explode.
It also contains acid that could burn or disfigure you.
• Do not try to install, remove, charge or service your
truck battery unless you are trained and authorized.
• Never smoke or use an open flame around batteries.
Batteries produce explosive gas. • Your company should provide an area where it is safe
Do not smoke, use open flame, or
create an arc or sparks near this to work on batteries. Use that area for all battery work.
battery. Ventilate well in enclosed
areas and when charging. • Use protective equipment such as gloves, eye shields,
Batteries contain Sulfuric Acid which aprons etc.
causes severe burns. Do not get in
eyes, on skin, or clothing. In case of
contact, flush immediately. Get medical
attention if your eyes are affected.
107
BATTERY SIZE
WARNING
Make certain you use the correct size and weight battery.
Minimum battery size allowed
XXX mm (XX.XX in.) wide
Never operate a truck that has an underweight or undersized
XXX mm (XX.XX in.) long battery installed.
Undersize battery can affect truck
handling and stability. You could have
an accident.
Use U.L. classified Type EO battery.
Continued next page...
Battery Maintenance 36
Battery Maintenance continued Warning Labels

EACH WARNING LABEL

WARNI NG ON YOUR TRUCK IS IMPORTANT
Stay clear of all
moving parts. Read and obey all of them to protect
Moving parts can
cut or crush hands, yourself and others.
feet, arms or legs.
WARNI NG
WARNI NG 07

WARNI NG
Avoid being crushed during normal

Know the Hazards Standing or riding on the forks can

Falling objects or lowering forks can
cause serious injury or death.
Never stand under the forks.
WARNI NG
While servicing, block the forks so
they won't fall.
BEFORE CHARGING YOUR TRUCK BATTERY
10
truck operation. Stay within the
cause a fall. You can be seriously operator area. Stop truck completely
injured or killed. before getting off.
Never stand or ride on forks However, tipovers and falls from
for any reason. docks can cause serious injury or
09
even death. Immediately exit and
move away from the truck in these
emergencies.

It’s the law, you must be trained You can be trapped or crushed by
and certified to operate this truck. driving the operator area under racks

• Charge the battery only in areas designated for that use. (OSHA § 1910.178, Rev. 1999)

You or people around you could be

or other objects. Look where you are
going.

• See that the battery cells are filled to the proper level.
CAUTI ON
seriously injured or even killed if you
don't use this truck correctly. DANGER XXX

Connect charger
Obey all warnings and instructions on the truck

Never use an open flame to check the battery. properly orand

truck
can be damaged.
in the operator manual*.
Inspect your truck before starting work, make
Batteries can produce explosive gas. Do not
smoke, use open flame, or create an arc or sparks
Make certain near this battery. Ventilate well when in an enclosed
sure it is in good working order. area and when charging.
charger is plugged
• Make certain the charger is the same voltage and into the battery
* Additional copies of the Operators Manual and Truck
connector,Labels can be obtained from Crown Equip. Corp., New
not the WARNI NG
This battery contains Sulfuric Acid which causes
severe burns. Do not get in eyes, on skin, or clothing.
amperage as your battery. Bremen, Ohio 45869 U.S.A.
truck connector.
47
WARNING In case of contact, flush immediately and thoroughly
Attach block #77034 to Emergency disconnect
XXX
with water. Get medical attention if Connector
Battery your eyes are
Minimum battery size allowed lever will not work if
affected. block #77034 isn't
• Read the battery charger instructions. XXX mm (XX.XX in.) wide
XXX mm (XX.XX in.) long
20
bolted to the battery
half of the connector.

• Be sure the charger is turned OFF before connecting the

Undersize battery can affect truck
handling and stability. You could have
an accident.
WARNI NG Use (2) 1/4 x 1-1/4
Never use a battery
screws, lockwashers
without the block in
Use U.L. classified Type EO battery. place.
battery to the charger. Otherwise you might create a
& nuts.
Tilting mast forward 34

when forks are raised

and loaded can tip the
spark which could cause the battery to explode. truck over causing
injury or death.

Do not tilt elevated

load forward unless
it is over a stack.
BEFORE CONNECTING YOUR BATTERY
WARNING 14-001

Make certain the block (Crown #77034) is bolted to the

Attach block #77034 to Emergency disconnect
Battery Connector
lever will not work if back of the battery half of the connector. Without that
block #77034 isn't
bolted to the battery block the Power Disconnect won't work. In an emergency
half of the connector.
you will not be able to cut power to the truck.
Never use a battery
Use (2) 1/4 x 1-1/4

34
screws, lockwashers
& nuts.
without the block in
place. Make sure the truck key switch is turned off and all controls
are in the off position.
All rights reserved under International
and Pan American copyright conventions
Copyright 1996 Crown Equipment Corp.

37 Battery Maintenance continued Warning Labels 38